Compaction System with Determination of Compaction Progress

Abstract

A compaction system has a compaction device with an electric motor for generating a compaction movement, an energy device for providing electric energy for the electric motor, a measurement device for measuring the current drawn by the electric motor, and an evaluation device for evaluating the current draw as measured by the measurement device and for determining, from this determination, the compaction progress in the medium being compacted. The evaluation device is arranged at least partly in an external device, spatially separate from the energy device and/or from the compaction device.

Claims

1. A compaction system for the compaction of a medium, comprising: a compaction device with an electric motor that is configured to generate a compaction movement; an energy device that is configured to provide electric energy for the electric motor; a measurement device that is configured to measure a current drawn by the electric motor; and an evaluation device that is configured to evaluate the current draw as measured by the measurement device and to determine, from the evaluation, a compaction progress of the medium being compacted; wherein the evaluation device is arranged at least partly in an external device that is spatially separate from the energy device and/or from the compaction device.

2. The compaction system according to claim 1, wherein the energy device comprises a battery; the battery comprises a battery control electronics, forming one unit spatially with the battery; and the measurement device is integrated at least partly in the battery control electronics.

3. The compaction system according to claim 1, wherein the energy device comprises a converter that is configured to convert a current drawn from the energy device into a current suitable for the electric motor; the converter comprises converter control electronics forming one unit spatially with the converter; the measurement device is integrated at least partly in the converter control electronics.

4. The compaction system according to claim 1, wherein the evaluation device is configured to determine an operating state of the compaction device based on the respectively present electric current as detected by the measurement device.

5. The compaction system according to claim 1, wherein the evaluation device is configured to determine the respective operating state while considering the present electric current as detected by the measurement device and/or a respective current gradient determined from the detected electric current.

6. The compaction system according to a claim 1, wherein the evaluation device is configured to recognize whether a given compaction progress has been achieved.

7. The compaction system according to claim 1, wherein a communication interface is provided between the measurement device and the evaluation device, and wherein the communication interface is configured to transmit transmitting data to and/or back between the measurement device and the evaluation device.

8. The compaction system according to claim 1, wherein the external device comprises a human/machine interface that is configured to display ng information to an operator and/or to request information from the operator.

9. The compaction system according to claim 1, wherein a signal device is provided that is configured to generate a signal for the operator; the signal device is configured to generate the signal in dependence of a state of a process; and wherein the state of the process is selected from the group consisting of: that a compaction goal is achieved, that a compaction goal is not yet achieved, compaction is faulty, an error message.

10. The compaction system according to claim 1, wherein a documentation device is provided that is configured to record data generated by the measurement device and the evaluation device.

11. The compaction system according to claim 1, wherein an identification device is provided that is configured to identify the compaction device based on predefined profiles for the current flow.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] These and other advantages and features of the invention are explained in more detail below by way of examples with the aid of the figures. Wherein:

[0054] FIG. 1 shows a concrete compaction system serving as a compaction system according to the invention in schematic representation;

[0055] FIG. 2 shows a variant of the compaction system of FIG. 1; and

[0056] FIG. 3 shows an example of the change in current draw as a function of the different operating states of a concrete compaction device.

DETAILED DESCRIPTION

[0057] FIG. 1 shows a schematic representation of a concrete compaction system acting as a compaction system with an internal vibrator 1 and an energy device 2.

[0058] The internal vibrator 1 has an operating hose 3, at one end of which a vibrating head 4 serving as a housing is attached. Inside the vibrating head 4, an electric motor 5 is provided which drives an unbalance exciter 6 in rotation. The unbalance exciter 6 can be, for example, an unbalance shaft on which an unbalance mass is mounted eccentrically so that, when the unbalance shaft rotates, oscillations are generated which are introduced into the concrete to be compacted via the outer wall of the housing of the vibrating head 4. The construction of such a vibrating head 4 with electric motor 5 and unbalance exciter 6 is known in itself.

[0059] The operating hose 3 can comprise a length of several meters, so that the operator can also suspend the vibrator head 4, over a greater distance, in the concrete to be compacted during the compaction work. FIG. 1 is, moreover, not to scale and does not reflect the actual length of the operating hose 3.

[0060] A switching device 7 is attached to the end of the operating hose 3 opposite the vibrator head 4, via which switching device the electric motor 5 can be switched on and off. The switching device 7 can also serve as a connection point for a power line 8 (power cable). The electrical leads of the power line 8 are routed inside the operating hose 3 to the vibrator head 4, so that the operating hose 3 also takes on the function of a protective tubing.

[0061] At the end of the power line 8 opposite the switching device 7, a plug not shown in FIG. 1 may be provided in a manner known per se. The plug may be plugged into the power device 2.

[0062] In the example shown in FIG. 1, essential parts of the power device 2 are arranged on a supporting device 9, which can be carried by a user, for example, on their back, by way of carrying straps 10, in a manner similar to a backpack. In this, the supporting device 9 can comprise a carrying frame that reliably bears the components attached to it. This is also described, for example, in DE 10 2018 118 552 A1 and its U.S. counterpart US20200044206A1, the subject matter of each of which is incorporated herein in its entirety.

[0063] A rechargeable battery 11 is fastened to the supporting device 9 as an electrical energy storage device. The rechargeable battery 11 represents a central part of the energy device 2 and can be exchangeable and when exhausted, switched out with a fresh rechargeable battery 11.

[0064] Instead of the rechargeable battery 11, it is also possible to provide an electrical supply via the public power grid or a power network existing at the construction site.

[0065] Furthermore, the supporting device 9 bears a converter 12 which, in particular, converts the current drawn from the rechargeable battery 11, in terms of voltage and frequency, in a manner suitable for the electric motor 5. This converted current is then supplied by the converter 12 to the electric motor 5 via the power line 8.

[0066] Symbolically, a measurement device 13 and a vibration device 14 are also arranged on the supporting device 9. The measurement device 13 and the vibration device 14 do not need to be arranged as physically separate components on the supporting device 9. Rather, they can also be arranged in the rechargeable battery 11 or alternatively in the battery management system of the rechargeable battery 11 or also in the converter 12 or also elsewhere.

[0067] A mobile device 15, for example, a smart phone or a tablet, acting as an external device, is provided in spatially separated manner, in which mobile device an evaluation device 16 can be provided. The measurement device 13 and the evaluation device 16 together form a compaction recognition device. In particular, the evaluation device 16 may be installed as a program or alternatively as an app on the mobile device 15.

[0068] A transmitting and receiving device 17 is provided on the rechargeable battery 11 for coupling the mobile device 15 with the energy device 2. A data transmission 18 acting as a communication interface, to the mobile device 15 and in particular to the evaluation device 16 can be achieved with the aid of the transmitting and receiving device 17.

[0069] The measurement device 13 and the evaluation device 16 together form a compaction recognition device for recognizing progress of the compaction in the concrete. The measurement device 13 is thus able to monitor the consumption of current of the electric motor 5 during compaction operation. Since modern rechargeable battery systems often comprise a battery management system that very precisely documents the consumption of current, the measurement device 13 can accordingly also be integrated in the rechargeable battery 11 or use the battery management system there. The resulting data is transmitted via data transmission 18, for example, a radio link (Bluetooth), to the mobile device 15 and there to the evaluation device 16. The mobile device 15 provides sufficient computational capacity to allow the evaluation device 16 to perform the necessary calculations. By way of example, the evaluation device 16 can be installed as an app on the mobile device 15 and perform the calculations.

[0070] When the evaluation device 16 recognizes that the progress of the compaction is satisfactory and a prescribed degree of compaction has been achieved, the evaluation device 16 then sends a signal to the vibration device 14. The vibration device 14 is capable of generating a suitable haptic feedback signal that can be haptically perceived by the operator of the internal vibrator. The vibration device 14, likewise, need not be a physically separate component, but rather may be integrated into the other components, in particular, for example, into the converter 12 or alternatively into a control system of the converter 12 that is not shown. It serves only the functional task of generating the haptic feedback signal.

[0071] For this purpose, the signal from the evaluation device 16 about the achievement of the prescribed progress of the compaction can be received by the transmitting and receiving device 17 on the rechargeable battery 11 and forwarded to the converter 12, which then increases or reduces the rotational frequency of the electric motor 5. The increase or decrease of the rotational frequency can be done abruptly or continuously or combined with variable time intervals to inform the user about the progress of the compression. For example, it is possible to generate Morse code-like signals by changing the rotational frequency to inform the operator about the progress of the compression.

[0072] The change in engine rotational frequency leads to a change in the oscillation frequency of the internal vibrator 1. Since the operator guides the internal vibrator 1 on the operating hose 3 or on the switching device 7 by hand, the change in oscillation frequency is directly perceived as a vibration and can then be interpreted accordingly by the operator.

[0073] If the system recognizes that no further compaction is possible or useful at the current position of the internal vibrator 1 or of the vibrator head 4, a repeating pattern of fluctuating frequencies can be set to signal to the operator that the internal vibrator 1 should be used at a different position. The operator can thereinafter move the vibrator head 4 to an area of still uncompacted concrete using the operating hose 3.

[0074] In one variant, the vibration device 14 can, irrespective of a change in engine speed, also generate an independent oscillation similar to the vibrate alarm on a smartphone. For this purpose, the vibration device 14 can activate a small unbalance exciter (not shown), which is provided, for example, on the supporting device 9 or even on the switching device 7, so that the operator can feel the vibration with their back or their hands.

[0075] The mobile device 15 is not mandatorily necessary. It is likewise possible to also integrate the evaluation device 16 into the energy device 2, for example, into the battery management system of the rechargeable battery 11, if sufficient computational capacities are available there.

[0076] The rechargeable battery 11 can be configured in such a way that it can communicate with the connected converter 12 as well as with the mobile device 15. The necessary measuring devices can be integrated in the rechargeable battery 11 in order to sample the electrical power consumption with sufficient accuracy.

[0077] The communication between the rechargeable battery 11 or alternatively the transceiver 17 of the rechargeable battery 11 on the one hand and the mobile device 15 on the other hand is bidirectional by means of the data transmission 18 (communication interface), so that the results of the calculations or signals based thereon can be reported back from the external mobile device 15 to the rechargeable battery 11 or also to the converter 12 connected thereto.

[0078] As a result, the concrete compaction system is able to tangibly signal to the user that sufficient compaction has been achieved at the current position of the internal vibrator 1 or alternatively of the vibrator head 4. As a result, the compaction process can be carried out efficiently.

[0079] FIG. 2 shows in schematic representation another concrete compaction system, that is nonetheless similar to FIG. 1, having an internal vibrator 1 and an energy device 2. The same or similar features of the concrete compaction systems of FIGS. 1 and 2 are given the same reference numbers. There is no need to repeat the description of the same or similar components.

[0080] Symbolically, a current detection device 13, an evaluation device 16 and an interpretation device 17 are also provided in FIG. 2 on the energy device 2. These components can also be located elsewhere on the internal vibrator 1 or alternatively the concrete compaction device. However, their arrangement in the vicinity of the rechargeable battery 11 or alternatively of the converter 12 lends itself well in order to, there, precisely detect and interpret the current drawn by the electric motor 5.

[0081] The current detection device 13, the evaluation device 16. and the interpretation device 17 need not be physically separate components. Rather, they may also be arranged in the rechargeable battery 11 or in the battery management system of the rechargeable battery 11, or in the converter 12, or elsewhere. By way of example, the evaluation device 16 and the interpretation device 17 can also be spatially arranged elsewhere, for example, as a software application on a smartphone that is acting as mobile device 15 (for example a smartphone), carried by the operator of the internal vibrator. In this case, the communication link or alternatively communication interface in the form of the data transmission 18 must be provided to transmit the current values detected by the current detection device 13 to the evaluation device 16.

[0082] The current detection device 13 is used to detect the electric current absorbed by the electric motor 5. It is possible to detect the current in short sampling intervals, in order to obtain the most precise current profile possible.

[0083] The measurement results of the current detection device 13 are passed on to the evaluation device 16, which can detect an operating state of the internal vibrator based on the then currently detected electric current (current values and current flow or alternatively current gradient), as explained below with reference to FIG. 3.

[0084] The interpretation device 17 is intended to interpret the current flow during a compaction process. In particular, the interpretation device 17 is intended to recognize and classify the compaction state during the compaction process.

[0085] When the interpretation device 17 determines that the concrete is currently sufficiently compacted, a signal device, not shown, can be used to signal the operator of the internal vibrator 1 to stop compaction at the corresponding location and continue compaction at another location.

[0086] Information relating to the state of compaction may be communicated to the operator in various ways. For example, the corresponding data can be displayed to the operator via assistance systems, for example, by applications installed on smartphones. In addition, logging of the measurement results for later documentation is also readily possible.

[0087] By way of example, FIG. 3 shows the flow of the current drawn by the electric motor 5 over time during various operating states of the internal vibrator 1. The respective current values can be detected by the current detection device 13 with short sampling intervals.

[0088] During phase a, the internal vibrator runs in the air and is not immersed in the concrete (idling phase, operation of the electric motor at no load, positioning of the vibrator housing in the air). In this phase, the absorbed current is constantly low.

[0089] During immersion of the vibrator housing in the concrete (phase b), the current draw increases and reaches a detectable maximum.

[0090] If the internal vibrator subsequently dwells in the concrete (compaction process), the concrete is compacted in the effective range of the vibrating head 4 (phase c). A partially decreasing current flow can be recognized, with a negative current gradient.

[0091] On the basis of the changing current gradients (current drop), the progress of the compaction process can be concluded by the evaluation device 16 in conjunction with the interpretation device 17. The further the compaction process progresses, the flatter the curve progression becomes, which is to say the current gradient approaches zero value. In this, the current absorbed always remains greater than in the idling phase in the air (phase a), so that the states of idling (phase a) and immersed or alternatively compaction (phase c) can always be clearly distinguished from one another.

[0092] When the vibrating head 4 emerses from the concrete (phase d), a brief increase in current can be observed due to the change in position of the vibrating head 4. Subsequently, the current absorbed falls back to the value corresponding to no-load operation as soon as the internal vibrator is in the air again. Finally, the current draw changes again to the no-load phase (phase e).

[0093] In particular, in the case of a portable energy device provided in a backpack system with an energy storage device that can be used to operate internal vibrators, measurement devices, for example, in the battery control electronics, are usually already present with which the input power can be measured in the form of current and voltage for operating the internal vibrators. Additional sensor technology, in particular, in the vibrating head or the protective tube, is not required.

[0094] Due to the high measurement accuracy and sampling rate, it is possible to infer from the current flow the operating state (no-load, immersion, dwell, emersion) and the compaction progress of the internal vibrator in the concrete. To determine the respective operating state, the measured values or alternatively their curves and changes are compared with known values or, alternatively, patterns.

[0095] The measurements can be carried out in a suitable manner for rechargeable battery-powered internal vibrators, but also for mains-powered internal vibrators.

[0096] The compaction system allows a multiplicity of combinations and working methods, which shall be explained in the following in order to add to and extend the previous remarks.

[0097] While the system formed by the rechargeable battery and the frequency converter (the connected internal vibrator is considered to be an actuator and can be switched on and off by the user) is active, the current flow and the input voltage are detected with a high sampling rate. The measurement equipment needed for this can be accommodated in the battery management system or alternatively in the frequency converter.

[0098] For the interpretation, the measured data can be sent by means of the communication interface in the rechargeable battery system to a further device (such as a smartphone, computer, smartwatch or the like) already present at the user, having the necessary computing power as well as a suitable application for the evaluation. Depending on the kind of evaluation, computing operations and/or operations of comparison with memorized profiles, especially current or current flow profiles, are possible.

[0099] In the case of power-grid-operated equipment, the measurement device and the communication interface can be integrated in the converter.

[0100] The external equipment (external device) can serve at the same time as an expanded human/machine interface for the displaying and requesting of information and boundary conditions needed for the determination of the compaction progress and for its documentation, such as the concrete consistency or the type of internal vibrator used.

[0101] The reaching of a suitable degree of compaction for the application can also be signaled through the external device, especially acoustically, optically, or by use of a vibration generator, if such is present in the device.

[0102] The user can also be informed if the last compaction process (beginning with the immersing of the internal vibrator and ending with the emersing) was inadequate or faulty, so that they can repeat this if necessary.

[0103] A documentation can be enabled for example by recording the number of compaction processes as well as evaluating which compaction processes were successful. Thanks to the use of the Internet connection of the external device, the compaction data can be transmitted to other devices or a corresponding cloud. This enables, in addition to the central documentation, also a simultaneous monitoring of the compaction processes and an ongoing adaptation.

[0104] Unlike the concept as described in EP 2 574 916 A2, the determination of the compaction quality is not carried out solely with the aid of the switched-on time of the internal vibrator, but instead by determining the compaction progress and the state of the equipment based on the interpretation of the current flow as well as with the data indicated by the user as to the internal vibrator being used and the concrete grade or alternatively concrete consistency.

[0105] The communication between the rechargeable battery and the external unit can be bidirectional, so that the results of the computations or signals based on them can be reported back from the external device to the rechargeable battery or also to the frequency converter connected to it.

[0106] In the case of compaction systems with power grid operation, i.e., without rechargeable battery, the measurement of the parameters can be done in the frequency converter, with a direct communication to the external device.

[0107] A measurement of the parameters in the frequency converter is also possible, in which case the data can be communicated via the rechargeable battery to the external device. In this case, the rechargeable battery plays the part of a gateway.

[0108] Artificial intelligence or machine learning can be used for the evaluation and interpretation of the current values or profiles when determining the compaction progress.

[0109] In one variant, an automatic identification of the type of vibrating head connected is possible with the aid of memorized profiles for the current flow (running in the air/surge in current in the concrete). In this case, no user input is needed, as long as the type of internal vibrator is known to the system.

[0110] Furthermore, in one variant the concrete grade can be recognized with the aid of the resulting current flow. Here as well, no user input is required.

[0111] The data can be evaluated and processed in an external network or a combination of networked systems or a cloud.

[0112] The interpretation and/or documentation of the compaction progress of ground compaction equipment (vibration plates, vibration pounder, vibration roller) is possible with the aid of the measured current flow.

[0113] In particular, the determination of the compaction progress and/or the state of compaction machines can be done with the aid of measured electric parameters and corresponding computing and comparison operations.

[0114] The determination of the compaction quality can be done by dependency simulation of representative measured quantities, especially with the aid of the current flow detected in the existing rechargeable battery system. The dependency of the current flow or alternatively the power absorbed by the internal vibrator in relation to the degree of compaction is influenced by multiple parameters. If all parameters are known (e.g., the characteristic curve of the internal vibrator being used), the present degree of compaction can be calculated or simulated based on the known and presently measured values.

[0115] According to the invention, measurement devices can be used which are installed in any case, e.g., for their own protection, in the corresponding devices (e.g., internal vibrators). In this way, it is possible to do without additional sensors in the vibrating head or in the protective hose.

[0116] A largely automated documentation of concrete compaction processes with internal vibrators is possible, without the use of costly additional hardware. The use of already present internal vibrators also becomes possible, since no retrofitting of sensors is required. The necessary computing operations can be performed on an external terminal device, such as a smartphone

[0117] The compaction system can constitute the basis for assistance systems which report to the user that sufficient compaction has been achieved at the present position of the internal vibrator. In this way, increased efficiency can be achieved in the compaction process and increased safety for load-bearing structures.

[0118] One essential idea is the use of computing power which the user generally also carries around, such as in the form of their smartphone. This eliminates further costs for the computing power which is needed in particular for the evaluation device and optionally the interpretation device. Resources can be saved.